CONTENTS

 SYNOPSIS
 INTRODUCTION
 LITERATURE SURVEY
 CONSTRUCTION DETAILS
 FABRICATION OF PARTS
 ASSEMBLY OF COMPONENTS
 WORKING PRINCIPLE
 LINE DIAGRAM
 LIST OF MATERIALS
 ADVANTAGES
 APPLICATIONS
 PHOTOGRAPH
 COST DETAILS
 CONCLUSION
 BIBLIOGRAPHY
 SYNOPSIS

Energy is the primary and most universal measure of all kinds of work by

human beings and nature. Solar energy is one of the non – conventional energy

source; this will eco-friendly and also reduce the cost of electric power. In this

project is to design and fabrication of auto charging grinding machine powered

by solar power. The model is developed by using Creo software and

AUTOCAD, and then fabrication is carried out this model. Our grinding

machine is fabricated to grind different materials and size of the job. The

grinding wheel is rotated by single phase DC motor. 12V DC battery powers

the DC motor. The battery is charged by using Solar panel and alternator

which is coupled to the grinding machine shaft.

 INTRODUCTION

Aim of the research work is to design and fabricate auto charging grinding

machine. It is used to grind the machining surfaces to super Finish and

accuracy. The principle parts of this attachment are main body, motor with

pulley, bearings, rope pulley and alternator etc. So this project solar powered

auto charging grinding machine is very much useful, since it is provided with

good quality of power sources and simple operating mechanism. Hence each

and every drop of fuel saves our economy and meets the needs is the saturation

point that is to be attained as soon as possible.

In order to achieve this saturation point we have to save and seek for some

other source of power. This power, the alternate power must be much more

convenient in availability and usage. The next important reason for the search

of effective, unadulterated power are to save the surrounding environments

including men, machine and material of both the existing and the next fourth

generation from pollution, the cause for many harmful happenings and to
reach the saturation point. The most talented power against the natural

resource is supposed to be the electric and solar energies that best suit the

automobiles. The unadulterated zero emission electrical and solar power, is the

only easily attainable alternate source. [1]

Hence we decided to incorporate the solar power in the field of automobile,

the concept of many Multi-National Companies (MNC) and to get relieved

from the incorrigible air pollution. Need for non-conventional energy sources.

Energy is the primary and most universal measure of all kinds of work by

human beings and nature. Everything what happens in the world is the

expression of flow of energy for input to their bodies or to the machines and

thinks about crude and electric power. The energy sources available can be

divided into 3 types [2]:

1. Primary Energy Sources

2. Secondary Fuels

3. World Energy Future

A. PRIMARY ENERGY SOURCES:

Primary energy sources can be defined as sources, which provide a net energy.

Coal, Oil, uranium etc., are examples of this type. The energy required to
obtain these fuels is much less than what they can produces by combustion or

nuclear reaction. Their energy yield ratio is defined as the energy feedback by

the material to energy received from the environment becomes very essential

to use these fuels sparingly. Primary fuels contribute concededly to the energy

supply.

B. SECONDARY FUELS:

It produces no net energy though it may net energy yield ratio and those

highest investments in terms of energy. Insulation is an example for this

source. Coal, Natural gas, Oil and Nuclear energy using Breeder reactor are

net energy yielder and are primary sources of energy. Secondary sources like

solar energy, Wind energy, Water energy etc. Solar energy can be used through

plants, solar cells and solar heaters. Solar tower is another emerging

technology. Solar drying and solar heating are economical applications when

passive methods are used. Because of dilute nature of solar energy it is

difficult to classify the sources as primary one. Better sources are wind. Tidal,

wave and hydroelectric application, Geothermal and ocean thermal are other

sources, which may well prove worthwhile. It may be necessary in future to

develop the secondary sources like solar, wind etc. Energy is an important

input in all sectors of any country economy. The standard of a given country

can be directly related to per capital energy consumption. Energy crisis is due
to two reasons first the increase of population and the second is the standard of

living of human being has increased. The supply of oil will fail to meet the

increasing demand before the year 2020 even if energy crisis rise 50% above

current levels in real terms. Additional constraints on oil production will

hasten this shortage, thereby reducing the time available for action on

alternatives. Electricity from nuclear power is capable of making an important

contribution to the global energy supply although worldwide acceptance of it,

on a sufficiently large scales yet to be established. Fusion power will not be

sufficient before the end of 2020. [7]

C. WORLD ENERGY FUTURE:

If present trend continues, the world in the year 2020 A.D. will be more

crowded than that of today. The world population may reach 10 billion by

2020 A.D. the conventional energy sources are depleting and may be

exhausted by the beginning of next century. Nuclear energy requires skilled

technician and poses the safety as regards to radioactive waste disposal. Solar

energy and other non-conventional energy sources are to be utilized in future.

Coal has the potential to contribute substantially to the future energy supplies.

Coal reserves are abundant but taking advantages of them requires an active

program of development by both producers and consumers. Natural gas

reserves are large enough to meet projected demand provided the incentives
are sufficient to encourage development of extensive and costly inter-

continental gas transportation system. Other than hydroelectric power,

renewable resources of energy example solar, wind, wave are unlikely to

contribute significant quantities of additional energy during the century at

global level although they could be of importance in particular areas they are

likely to become increasingly important in the mid of 21st century.

II. SOLAR ENERGY

Solar energy has the greatest potential of the sources of renewable energy and

if only a small amount of this form of energy could be used.

Solar radiation is the diffusion radiation. The solar power where sun hits

atmosphere is 10¹⁷ watts. Whereas the solar power on earth’s surface is 10¹⁶

watts. The total worldwide power demand of all needs of civilization is 10¹³

watts. Therefore the sun gives as 1000 times more power than we need. The

sun radiates energy as electromagnetic waves of which 99 percent have

wavelengths in the range of 0.2 to 4.0 meters. Solar energy reaching the top of

the earth’s atmosphere consists of about 8 percent ultraviolet radiation, 46

percent visible lights, and 46 % infrared Radiation. If we use only 5% of

energy it will be 50 times what the world will require. The energy radiated by

the sun on a bright sunny day is approximately 1 km/m². Now days the
drawbacks as pointed out that energy cannot be stored and it is a dilute form of

energy, are not dated arguments. Utilization of solar energy is of great

importance to India, since of lies in a temperature climate of the region of the

world where sunlight is abundant for a major part of year. Solar energy is a

time dependent and intermitted energy Resource.

Figure 1:
METHODS OF UTILISATION OF SOLAR ENERGY

1. DIRECT METHOD

a. Photo Voltaic Method

b. Thermal Method

2. INDIRECT METHOD

a. Water Power Method

b. Wind Power Method

c. Bio Mass Method

d. Wave Energy Method

e. Ocean Power Method

DIRECT METHOD OF UTILIZATION OF SOLAR ENERGY:

The most useful way of harnessing solar energy is by directly

converting it into electricity by means of solar photovoltaic cells.

Sunshine is incident on Solar cells, in this system of energy

Conversion that is direct conversion of solar radiation into electricity.

In the stage of conversion into thermodynamic from is absent. The

photo-voltaic effect is defined as the generation of an electromotive

force as a result of the absorption of ionizing radiation. Energy

conversion devices, which are used to convert sunlight to electricity

by use of the photo-voltaic effect, are called solar cells.

In recent years photo-voltaic power generation has been receiving

considerable attention as one of the more promising energy

alternatives. The reason for this rising interest lie in PV’s direct

conversion of sunlight to electricity, the non polluting nature of the

PV widespread are of PV generation has been hampered by economic

factors. Here to force, the low cost of conventional energy sunlight

has obviated the development of a broad-based PV technology.

At the present time, PV generation can be justified only for special

situations mostly for remote sites where utility lines on other

conventional means of furnishing energy may be prohibitively

expensive and is one of the most attractive nonconventional energy

sources of proven reliability from the micro to the Mega-watt level.

Like other energy system this system also has some disadvantages

(1) Distributed nature of solar energy,

(2) Absence of energy storage,

(3) Relatively high capital cost

PHOTO VOLTAIC METHOD:

PHOTOVOLTAIC PRINCIPLES: The photo-voltaic effect can be

observed in nature in a variety of materials that have shown that the

best performance in sunlight is the semiconductors as stated above.

When photons from the sun are absorbed in a semiconductor, that

create free electrons with higher energies than the created there must

be an electric field to induce these higher energy electrons to flow out

of the semi-conductor to do useful work. A junction of materials,

which have different electrical properties, provides the electric field

in most solar cells.

III. GRINDING MACHINE

A grinding machine, often shortened to grinder, is any of various

power tools or machine tools used for grinding, which is a type of

machining using an abrasive wheel as the cutting tool. Each grain of

abrasive on the wheel's surface cuts a small chip from the work piece

via shear deformation.

Grinding is used to finish work pieces that must show high surface

quality (e.g., low surface roughness) and high accuracy of shape and

dimension. As the accuracy in dimensions in grinding is of the order

of 0.000025 mm, in most applications it tends to be a finishing

operation and removes comparatively little metal, about 0.25 to 0.50

mm depth. However, there are some roughing applications in which

grinding removes high volumes of metal quite rapidly. Thus, grinding

is a diverse field.

Conventional grinding machines can be broadly classified as:

(a) Surface grinding machine

(b) Cylindrical grinding machine

(c) Internal grinding machine

(d) Tool and cutter grinding machine

III. FABRICATION

COMPONENTS

A.DC Motor

A DC motor is any of a class of rotary electrical machines that

converts direct current electrical energy into mechanical energy. The

most common types rely on the forces produced by magnetic fields.

Nearly all types of DC motors have some internal mechanism, either

electromechanical or electronic; to periodically change the direction

of current flow in part of the motor.

DC motors were the first type widely used, since they could be

powered from existing direct-current lighting power distribution

systems. A DC motor's speed can be controlled over a wide range,

using either a variable supply voltage or by changing the strength of

current in its field windings. Small DC motors are used in tools, toys,

and appliances. The universal motor can operate on direct current but

is a lightweight motor used for portable power tools and appliances.

Larger DC motors are used in propulsion of electric vehicles

,Figure 4: Fabricated Model

Figure 5: DC Motor

elevator and hoists, or in drives for steel rolling mills. The advent of

power electronics has made replacement of DC motors with AC

motors possible in many applications.

B. Alternator

An alternator is an electrical generator that converts mechanical

energy to electrical energy in the form of alternating current. For

reasons of cost and simplicity, most alternators use a rotating

magnetic field with a stationary armature. Occasionally, a linear

alternator or a rotating armature with a stationary magnetic field is

used. In principle, any AC electrical generator can be called an

alternator, but usually the term refers to small rotating machines

driven by automotive and other internal combustion engines. An

alternator that uses a permanent magnet for its magnetic field is called

a magneto. Alternators in power stations driven by steam turbines are

called turbo-alternators. Large 50 or 60 Hz three phase alternators in

power plants generate most of the world's electric power, which is

distributed by electric power grids.

Figure 6: Alternator

C. Solar Panel

Photovoltaic solar panels absorb sunlight as a source of energy to

generate electricity. A photovoltaic (PV) module is a packaged,

connected assembly of typically 6x10 photovoltaic solar cells.

Photovoltaic modules constitute the photovoltaic array of a

photovoltaic system that generates and supplies solar electricity in

commercial and residential applications.

A single solar module can produce only a limited amount of power;

most installations contain multiple modules. A photovoltaic system

typically includes an array of photovoltaic modules, an inverter, and a

battery pack for storage, interconnection wiring, and optionally a

solar tracking mechanism.

Figure 7: Solar panel

A single solar module can produce only a limited amount of power;

most installations contain multiple modules. A photovoltaic system

typically includes an array of photovoltaic modules, an inverter, and a

battery pack for storage, interconnection wiring, and optionally a

solar tracking mechanism.

Figure 8: Solar Panel Circuit

D. Battery

In our project we are using 12V Lead- Acid battery.

E. Grinding Wheel

A grinding wheel is a wheel composed of an abrasive compound and

used for various grinding (abrasive cutting) and abrasive machining

operations. Such wheels are used in grinding machines.

The wheels are generally made from a composite material consisting

of coarse-particle aggregate pressed and bonded together by a

cementing matrix (called the bond in grinding wheel terminology) to

form a solid, circular shape. Various profiles and cross sections are

available depending on the intended usage for the wheel. They may
also be made from a solid steel or aluminium disc with particles

bonded to the surface. Today most grinding wheels are artificial

composites made with artificial aggregates, but the history of grinding

wheels began with natural composite stones, such as those used for

millstones.

Figure 9: Grinding Wheel

The manufacture of these wheels is a precise and tightly controlled

process, due not only to the inherent safety risks of a spinning disc,
but also the composition and uniformity required to prevent that disc

from exploding due to the high stresses produced on rotation.

Grinding wheels are consumables, although the life span can vary widely depending on the use case,

from less than a day to many years. As the wheel cuts, it periodically releases individual grains of

abrasive, typically because they grow dull and the increased drag pulls them out of the bond. Fresh

grains are exposed in this wear process, which begin the next cycle. The rate of wear in this process

is usually very predictable for a given application, and is necessary for good performance.

S.NO COMPONENTS DESCRIPTION

1 DC Motor 12V-3000rpm
2 Alternator 12V-3000rpm
3 Bearing 25mm
4 Battery 12V Lead Acid
5 Shaft Mild Steel
6 Solar Panel 12V-24V Output
7 Frame Stand Mild Steel
8 Connecting Wires Copper
9 Bolt and Nut Mild Steel
10 Pulley 25mm

IV. WORKING PRINCIPLE

This machine is fixed on the work table, where the compound rest.

When the motor is on, the abrasive grinding stone and the roller

wheel will be rotated. The solar panel is used to store the electrical

energy to the battery. The battery gives the supply to the D.C motor

which is coupled to the generator and grinding machine with the help

of belt drive as shown in diagram

Figure10: Working Process

Solar energy means all the energy that reaches the earth from the sun.

It provides daylight makes the earth hot and is the source of energy

for plants to grow. Solar energy is also put to two types of use to help
our lives directly solar heating and solar electricity. Solar electricity is

the technology of converting sunlight directly in to electricity. It is

based on photovoltaic or solar modules, which are very reliable and

do not require any fuel or servicing. Solar electric systems are

suitablefor plenty of sun and are ideal when there is no main

electricity.

V. CONCLUSION

This report details with design and “solar powered auto charging

grinding machine” .The project carried out by us made an impressing

task in the shaping works of all types of work piece. It is very useful

for the small scale industries in order to minimize the manufacturing

cost by implementing the solar powered automatic grinding machines

to make shape of small elements after the machining process. This

project has been designed to perform the entire requirement task,

which has also been provided. This type of fixture is mainly used in

production field for grinding the all types of small scale elements

firmly and securely to perform operations and is mainly used in

manufacturing -oriented industries.

This project is focusing on solar powered grinding machine instead of

other electrical power sources. With the help of software Creo we

modelled and fabricated and the fabricated model will give the results

are listed below,

 Free of power

 Less maintenance

 Grind different size and materials

 Increase the speed up to 10000Rpm by changing the pulleys

 Eco friendly